Wall-forming structure



Jan. 19, 1965 D. J. VALSVIK 3,165,791

WALL-FORMING STRUCTURE Filed Nov. 15, 1960 4 Sheets-Sheet 1 I 7721672107" flonald 10025017; 5 w. W 12! Jan. 19, 1965 D. J. VALSVIK 3,165,791

WALL-FORMING STRUCTURE Filed Nov. 15. 1960 4 Sheets-Sheet 2 In z/en Zor ,Donald J Uaisvz'k ZfyU. din/(m 210 ney Filed Nov. 15, 1960 4 Sheets-Sheet 3 177 ms 175 157 z f I 2 x v r Fi .15 Inventor Donald J UaZsvZ'l" 5 w rizey r FIG.

United States Patent() 3,165,71 WALL-ORMTNG STRUCTURE Donmd J. Valsvik, Stiliwater, assignor to Wood Conversion Company, St Paul, Minn, a corporation of Delaware Filed Nov. 15, 195i), Ser. No. 69,445

. 1t) Claims. (Cl. 28-4) The present invention relates to panel-wall construction and in particular to a combination of wall-forming elements which may be applied over a face formed by at least two parallel Wall-defining framing members or studs, said combination including means for entering the interstud space for providing thermal insulation and other advantages.

In frame structures in which walls are provided with parallel spaced wall-defining members, such as. studs, one face is conventionally covered by sheathing and the sheathing [then covered with siding. Thermal insulation material is set in place between the studs, usually in blanket form. Such blanket insulation may be set in place either from the inside wall face, orsornetimes from the outside wall face before application of sheathing, according to the design of the insulation blanket It is an object of the present invention to reduce the number of separate applications of material to form a closed wall.

A particular object of the invention is to provide a combination of sheathing-like face covering which when applied over a stud face carries with it into the interstud face thermal insulating means.

The invention may be carried out in numerous ways, as set forth in the accompanying drawings, in which:

FIG. 1 shows a cross-section of a wall structure to which has been applied the structure of FIG. 2.

FIG. 2 represents a combination of rigid facing means for a wall with attached movable material to form an insulating air space after mounting the facing material.

FIGS. 3 and 4 are similar to the showing of FIGS. 1 and 2, to illustrate a modification of the structure.

FIGS. 5 and 6 are simiiar in showing to FIGS. 1 and 2, illustrating a second modification of the structure.

FIGSF7 and 8 are similar in showing to FIGS. 1 and 2, illustrating a third modification of the structure.

FIGS. 9 and 10 are similar in showing to FIGS. 1 and 2, illustrating a fourth modification of the structure.

FIGS. 11 and 12 are similar in showing to FIGS. 1 and 2, illustrating a modification of the structure shown in FIGS. 3 and 4.

FIG. 13 shows a slight modification of the structure of FIG. 14 shows a mounted structure similar to that of FIG. 1, with non-uniform dimensions at the two sides.

FIG. 15 shows the unmounted structure of FIG. 14.

FIG. 16 illustrates sheet material comprising metal foil lining both faces of lcraft paper.

FIGS. 17 and 18 are similar to FIGS. 14 and 15, showing a modification for the nailing flange.

In the following description, the framing members are exemplified by reference to the studs which define the walls of frame buildings, and for which the preferred embodiments are designed. However, it is to be under stood that the invention is not so limited.

FIG. 1 shows two parallel studs 1%) and llwhich with like studs provide a wall face. Numeral-lz designates rigid facing, such as sheathing to provide the first course of external wall covering. The facing 12 may cover tion id over stud 11 to be nailed thereto.

In the installed position of FIG. 1, there is sheet mt.-

terial l6 spanning the space between studs it? and 11 at "ice.

a distance designated 2x from the facing 12. The space 1'7 etween s eet 16 and facing 12 provides thermal insulation, especially when 2x is not greater than about At-inch. The sheet 16 provides wind-proofing; When the sheet 16 has a reflective face 26, such as that of aluminurnfoil, it provides additional insulation value, and when used as shown, it provides a moisture-vapor seal. 1 I

The spanning sheet 16 is so constructed that it is foldable flat onto the face 22 of the facing 12 and is preferably so positioned when the facing 12 is secured to the studs it? and 11. It is also so related to the facing 12 that it may be moved into the position of FIG. 1 and in that position secured to the side faces of studs 1i and 11.

Various constructions may be used to effect the foregoing operations and structure. One of these is shown in FIGS. 1 and 2. v

As shown, the sheet lid, preferably of reflective-metal foil-faced kraft paper, is continuous from an edge 24- substantially coincident with facing edge 13, to provide several spanning panels such as that shown in FIG. 1. The edge-strip 26 of sheet 16 is secured to a corresponding edge portion of facing-12,01 .13 over the area to lie over stud iii. As shown in the folded position of FIG. 2, there is secured to an adjacent strip portion 28 of the sheet material 1-5 a reinforcing or nailing" strip 30 ex:

tending beyond a line 32 in sheet 16 for folding sheet 16 in a first direction from a planar position. Between the stripportions 26 and 28, there is a folding line 34 parallel to line 32 for folding sheet 16 in the opposite direction. There is also a third parallel foldinglinefi V for folding sheet 16 in the second direction from a planar position. The folding lines 32 and 34 are spaced apart" 36 are spaced by the said distance 2x, and the lines 32 and apart by the distance x.

By reason of the structure and dimensions above described, the sheet 16 may lie flat on facing 12 as in FIG. 2, when nailing the facing to studs. Then, the projecting portion of the nailing strip 36 may be hingedon hingingline 34 to contact a face of a stud to which it is secured by suitable means such as staples 4%.

The structure at stud 11 is exactly the same except that the portion of sheet 16 which corresponds to end strip 26 continues as a seal over the stud to repeat the structure at stud H, where more than one stud space is covered by a combination unit.

v slightly beyond the wall face of stud 44 to a folding line 56 and continues thus defining a strip portion 53 between The'spacing of studs as 1% and 11 may not always be exact, as illustr-ated by studs 44 and 46 of FIG. 3, and the structure may be varied to accommodate variations.

Sheathing 48 has a coincident edge strip Stl-united to edge strip 52. of sheet material-54, comparable to sheet 16. The ed e strip 52 of the sheet material extends line -56 and a second folding line Gil in sheet material 54. Ast-iif but yet flexible nailing strip 62 is secured to the strip 58 and extends as a fork member unsecured beyond folding line or fork line 60, The sheet material 54 is stretchable by reason of corrugations or creping 64 for a suitable portion of its interstud width so as to be stretched to lie taut across the interstud space and spaced away from facing 48. f V

At stud 46, thecomparable structure continues to repeat the structure at stud 44 where more than one stud space is covered by a combination unit. i

FIG. shows the structure of FIG. 3 before mounting it to the studs. After the facing 48 is secured to the studs, the projecting edge strip 62 of each reinforcing strip 62 is lifted and its remainder and the strip 58 of the sheet material are hinged on line 5s. They are calculated not to he fiush on studs exactly spaced, and in consequence, may

' befiexed so that the projecting portions 62' lie flush on means 136 secured thereto.

the studs to be securedthereto as by nails 64. The stretchable portion is thus expanded sufficiently to form the structure of FIG. 3.

FIGS. and 6 show modified structures wherein the sheet material itself is reversely folded to form a laminated flange for nailing, which flange may be internally reinforced.

In FIGS. 5 and 6, only the end structures are shown, 'as these modify the end structures of FIGS. 1 and 3.

In FIG. 5, the stud 63 has nailed to it the facing material 70 on the edge strip 72 of which is carried edge strip 74 of sheet material 76, spaced away from facing material 76 by the distance 2a. At the corner of stud 63, a fold 78 in the sheet material provides a strip 86 of width 2a+b, terminating in a double-backed fold 32. Then folding line 84 forms a strip 86 of width b. Beyond line 84 a third folding line 88 forms strip 9!) of Width :1. With suitably thick sheet material 76, the nailing flange 31P-86 is sufficiently strong for nailing or stapling it to the stud. Optionally, a reinforcing strip 89 may be secured within the flange 80-36 and when used, it preferably extends from reverse fold 82 to the folding line 78, and is secured to strip 88.

FIG. 6 shows the structure of FIG. 5 flat-folded.

FIG. 7 shows a structure of FIG. 8 united to stud 313". Facing material 92 has its edge strip 94 united to edge strip 96 of sheet material 98 from their common edges to folding line 1% in sheet 98. Line 190 is sli htly spaced from stud 90. Beyond folding line 100, there is in sheet 98 a stud-strip 102, a reverse fold 104, a strip 166 narrower than strip 102, and a score line 168 for folding in the same direction as at line 199. In the folded form after application of the facing 92, to the studs, the nailing flange 11124136 is lifted to contact the stud, thereby stretching sheet material 98 at a corrugated or creped section 109. As in FIG. 5, an optional reinforcement such as heavy kraft paper 110 may be used to strengthen the nailing flange, and preferably, it is secured to the entire strip 102, as shown.

In the foregoing examples, the sheet material for spanning the interstud space extends to the positions where it eventually lies between a stud and the facing means. So positioned, it provides an excellent moisture-vapor seal where the sheet material itself so functions. However, other forms are contemplated.

In FIG. 9, the studs 111 and 112 are shown with facing means 114 secured thereto. At stud 111, the edge of a combination unit is shown, and at stud 112, the facing means continues onto the next stud. Secured to the facing means at positions to overlie the studs, are hinged strip form panels, which may be made of heavy paperboard, of which a first panel 116 is secured to said facing means at positions to overlie studs, and of which the second panel 118 may hinge away from said facing means so that at least the extreme edge thereof may be secured to the side face of a stud. The hinging line 129 between said panels is located substantially at the corner 122 of a stud. The spanning sheet material 124 is adhesively secured over the outer edge of panel 118 on both faces thereof, as indicated at 126, forming a nailing flange to be secured to a stud as shown. At a folding line 128, the sheet material is unsecured to the panel 118, and between the pair of adjacent folding lines 128 and 128, the sheet 124 has a width to span the interstud space. Folding lies 130 and 130' are provided in the sheet 124 for fiat-folding as shown in FIG. 10. The spacing of lines 128 and 130 is half the distance between lines 123 and 120, which latter distance is the spacing of the sheet 124 and the facing material 114 in mounted position.

A modification of the form shown in FIGS. 9 and is shown in FIGS. 11 and 12, in part for accommodating variations in stud spacing and for other reasons.

In FIG. 11, the studs 132 and 134 have rigid facing Prior to such mounting, hinged strip-form panel structures are secured to the facing means as shown in FIG. 12. The hinged panel structures each have a first panel 138 secured in position to overlie a stud and an unsecured second panel 140 positioned to be hinged to locate its outer edge against a side face of the stud. The panels have a hinging line 142 spaced slightly away from a corner 144 of a stud to ac commodate variations in stud spacing. In the flat folded position stretchable sheet material 146 having creping lines or corrugations 148, has its edge portion united to panel by adhesive 145 located as shown in FIG. 12, and in a manner to leave the extreme edge strip 147 unsecured to serve as a handle or lifting means. By grasping the strip 147, the panel 149 may be hinged out of its flat-folded position in FIG. 12. As it is lifted, the sheet 146 is stretched to span the interstud space at any desired distance from the facing means. By pushing a nailing cleat or the like 141 along panel 140 over the sheet 146, the sheet 146 moves toward the facing means 136 and stretches. Then, the cleat 154 or the like is nailed to the stud.

The structure shown in FIG. 12 has practical advantages in manufacture and in application, as will be apparent from inspection by those skilled in the art.

Where the facing means spans at least two interstud spaces, it is preferable that the hinged strip-form panel, whether it be the sheet material or the separate entity 116-113 of FIG. 9 or 138-149 of FIG. 11 be located to have its secured panel lie over the stud in mounted position. In each instance, the panel which is secured to the facing means may lie in the reverse direction from that illustrated. FIG. 13 repeats the left-end showing of FIG. 1, with the strip-section 26' of the sheet material 16 on the opposite side of its hinging line 34.

In the forms illustrated and described above, the structure conforms to commercial preferences in which the two edges of the facing sheet along the studs have duplicating dimensions. However, such duplication is not necessary and deviations from it may be resorted to, in order to avoid structures corresponding to those illustrated, for one reason or another.

FIG. 14 represents a form in which the stretch of sheet material mounted between the studs is not uniformly spaced from the face of the studs, and in which the folds in the spanning portion of the sheet are differently located. As this particular form is described and designated below, the preferred form becomes a spacial case thereof.

Numeral 159 represents facing means to be secured to the facing of the studs. As shown, it is such that it spans one interstud space and extends beyond the studs to cover the two adjacent interstud spaces. Secured to the facing means is sheet material 151 such as kraft paper 152 having aluminum foil 153 on both sides there of, as shown in FIG. 16. The sheet material 151 is secured to the facing means 159 at the regions corresponding to stud locations which locations are designated 156 and 158.

At the junction of the facing means 159 and the lefthand stud 160, there is a folding line 162 and beyond that at a distance x is a second folding line 163. To the portion of the sheet material 164 between said folding lines is a reinforcing strip 165 secured to the strip 164, the reinforcing strip extending beyond the folding line 163 to provide a flange for nailing or stapling to the stud as indicated by the nail 166. At the opposite stud 168, there is a folding line 170 at the corner of the stud at facing means and at a distance x from folding line 170, there is a second folding line 171 corresponding to folding line 163. To the strip of sheet material 172 lying between the folding lines 170 and 171 is secured a reinforcing strip 173 corresponding to the opposite strip likewise for nailing to the stud through the portion of strip 173 which extends beyond the folding line 171.

As shown, the distance x is greater than 2:, whereby the span of sheet material is slightly at an angle to the extent of the facing means 150. In order to collapse the structure there are provided additional folding lines in the sheet material, these being designated 175 at the left and 176 at the right. The distance between folding lines 163 and 175 is designated as y, being shorter than the distance x, and the strip between said folding lines being designated 177.

At the right-hand stud, the strip between folding lines '17 1 and 176 is designated 178 and itswidth is designated v, being less than x. The distance between folding lines 175 and 176 is designated 2.

In FIG. the numerical designations of the several strip portions of the sheet material 151 formed by providing said folding lines are omitted and only the algebraic symbols for their dimensions are given. The distance between the two studs is designated W. For any angular position of the sheet material including a zero In FIG. 14 the sheet 151 is positioned as the hypotenuse of a right-triangle having the sides W and (xx), and

In the preferred form x and x are equal, and y and v are equal, and in such case x=2y. Hence, y=x/2.

The structure shown in FIG. 14 may be modified by omitting the reinforcing strips, and providing a reverse fold in the sheet material for a mounting flange. One way is illustrated in FIGS. 17 and 18.

in FIG. 17, facing means 189 is shown secured to studs 181 and 182, with sheet material carried by the facing means at the location 134 and 185 of said studs.

At the inside corner of stud 181 at said facing means the sheet material 183 has a folding line 186 so that the sheet material maybe folded away from the facing means to lie on the stud. So positioned, it has a reverse fold 1S7 forming two layers, preferably secured together, to provide a nailing flange 137'. The inner edge of the nailing flange is defined by folding line 188, beyond which at a distance less than that between lines 186 and 188 is a folding line 189, which lies in the spanning portion of the mounted sheet material.

At the opposite stud, there are folding lines 199, 191, 192 and 193 corresponding to the lines 186, 187, 188 and 189, but at different separations such that folding line 192 is closer to the facing means 183 than is folding line 188. The reverse fold 191 forms a nailing flange 191' which is shown as being Wider than nailing flange 187, and as terminating at the same distance from the facing means 189 as does flange 187.

The relationship of dimensions given for FIGS. 14 and 15 apply to FIGS. 17 and 18, so that repetition of that description is not undertaken.

FIG., 18 shows the structure as folded before application to the studs.

From the foregoing it is apparent that all the forms provide a combination structure providing rigid sheathing with or without other facing means to produce exterior wall structure; that said combination includes a fiat-folded collapsible structure of sheet material which in flat-folded form on a face of the sheathing lies within the space between adjacent framing members to receive the sheathing; and that the collapsible structures may be opened or set-up after applying the sheathing element ing to the sides of the H, and the panel carried thereby corresponding to the cross-bar of the H- The invention pertains more to the combination of parts than to the selection of sheet material to provide the sheet spaced from siding which carries it. Ordinary paper will provide insulation by confining a space not over about %-inch thick. The method of mounting the sheet material provides a seal against wind and dust. The insulation effect may be greatly enhanced by providing reflective metal, such as foil, or sprayed-on flakes,

on one or preferably both sides of the sheet material. Plastic film may be used, as the sheet material. Asphalt coated or asphalted duplex paper may be used, and as such it provides resistance to the transmission of moisture vapor. The metal foils and some plastic films also may be used for such resistance. When using metal, as foil or flakes or powder, the sheet material to a degree resists radiation and in resisting dust also resists radiation from fall-out. These are all benefits to be obtained from the present invention, but not limitations thereof, as will appear in the appended claims.

I claim:

l. A wall-forming structure for covering a space of predetermined dimension in width, comprising rigid facing means having a width greater than said dimension, a spaced pair of foldable two-strip angular forms having their folding lines parallel and located at a face of said facing means and spaced apart by a distance the value of which is in the. immediate vicinity of said dimension but not greater than said dimension, each of said forms comprising a first strip secured to said facing means in position to locate said folding lines at said face, and said forms each further comprising a flange-forming mounting strip extending from its folding line, and an exterior expandable panel of sheet material having panel-edges connected to said flange-forming strips at hinging line's parallel to said folding lines and intermediate the edges of said flange-forming strips, said panel having an expandable width suitable to span said dimension when the outer edges of said flange-forming strips are spaced apart by said dimension, said panel being contracted in width between said hinging lines when said flange-forming strips are folded toward each other onto said face of said facing means.

2. A wall-forming structure according to claim 1 in which a single sheet forms said panel, portions of said flange-forming strips, and said first strips, and in which said flange-forming strips comprise reinforcing strips.

3. A wall-forming structure according to claim 1 in which a single sheet forms said panel, at least part of each of said flange-forming strips, and said first strips.

4. A wall-forming structure according to claim l in which the folding lines are spaced apart by a distance which is substantially said dimension.

5. A wall-forming structure according to claim 1 in which the folding lines are spaced apart by a distance which is slightly less than said dimension.

6. A wall-forming structure according to claim 1 in which said first strips at said face extend away from each other from their folding lines.

7. A wall-forming structure according to claim 1 in which the expanded width of said panel is a planar sheet and in which there are parallel spaced apart folding lines parallel to said hinging lines, the distance between each folding line. and its nearest hinging line being sufficiently less than the distance between said nearest hinging line and its folding line at said facing means for contracting said panel by folding so as to lie on said facing means when folding said'flange-forming strips toward each other onto said facing means.

8.,A wall-forming structure according to claim 1 in I: which said panel is a sheet wider than said dimension i and has an internal width-portion thereof corrugated at right angles to said dimensionwhereby said panel is expandable from said in-folded position.

9. A wall-forming structure for covering a space of predetermined dimension in width, comprising rigid fac ing means having a Width greater than said dimension, a spaced pair of foldable two-strip angular forms having their folding lines parallel and located at a face of said facing means and spaced apart by a distance the value of which is in the immediate vicinity of said dimension but not greater than said dimension, each of said forms comprising a first strip secured to said facing means in position to locate said folding lines at said face, and said forms each further comprising a flange-forming mounting strip extending from its folding line, and a connecting panel of planar sheet material extending from each of said flange-forming strips at hinging lines parallel to said folding lines and intermediate the edges of said flangeforming strips, said panel having a width between parallel edges substantially to span said dimension when the outer edges of said flange-forming strips are spaced apart by said dimension, said panel having two folding lines therein, a first one being spaced at distance y from the hinging line in a first one of said flange-forming strips which hinging line is a distance x from its folding line at said face, the second one of said two folding lines in said panel being a distance v from the hinging line in the second flange-forming strip which hinging line is a distance x from its folding line at said face, the distance between said folding lines in said panel being :5, the value at being greater than the value y, and the value x being greater than the value v, the value of x being not greater than the value x, the dimension for the width of said space being W, the value (xy+zv+x)=W, and the 10. A wall-formin structure for covering a s ace of first strip secured to said facing means in position to locate said folding lines at said face, and said forms each further comprising a flange-forming mounting strip extending from its folding line, and an exterior connecting panel of planar sheet material extending from each of said flange-forming strips at hinging lines parallel to said folding lines and intermediate the edges of said flange-forming strips, said panel having a width between parallel edges substantially to span said dimension when the outer edges of said flange-forming strips are spaced apart by said dimension, the hinging line and the folding line of each angular form being separated by a dis tance x, said panel having two folding lines each being inwardly from one of said edges by the distance x/2 for folding reversely to the folding at the hinging line in col lapsing the structure.

References Cited in the file of this patent UNITED STATES PATENTS 960,554 Jennings June 7, 1910 1,236,829 Evans Aug. 14, 1917 1,651,539 Olson Dec. 6, 1927 1,726,040 Olson 2. Aug. 27, 1929 1,894,592 Kilmer Jan. 17, 1933 1,913,312 Lines June 6, 1933 1,954,582 Aschenbrener Apr. 10, 1934 1,963,609 Balduf et al June 19, 1934 2,597,309 Fink May 20, 1952 2,739,703 Giles Mar. 27, 1956 2,749,262 Wiser June 5, 1956 2,777,786 Schwartz Jan. 15, 1957 2,782,914 Giles Feb. 26, 1957 2,879,554 Wheeler Mar. 31, 1959 3,017,020 Giles Jan. 16, 1962 FOREIGN PATENTS 370,527 Great Britain 1932 913,858 France a 1946 

1. A WALL-FORMING STRUCTURE FOR COVERING A SPACE OF PREDETERMINED DIMENSION IN WIDTH, COMPRISING RIGID FACING MEANS HAVING A WIDTH GREATER THAN SAID DIMENSION A SPACED PAIR OF FOLDABLE TWO-STRIP ANGULAR FORMS HAVING THEIR FOLDING LINES PARALLEL AND LOCATED AT A FACE OF SAID FACING MEANS AND SPACED APART BY A DISTANCE THE VALUE OF WHICH IS IN THE IMMEDIATE VICINITY OF SAID DIMENSION BUT NOT GREATER THAN SAID DIMENSION, EACH OF SAID FORMS COMPRISING A FIRST STRIP SECURED TO SAID FACING MEANS IN POSITION TO LOCATE SAID FOLDING LINES AT SAID FACE, AND SAID FORMS EACH FURTHER COMPRISING A FLANGE-FORMING MOUNTING STRIP EXTENDING FROM ITS FOLDING LINE, AND AN EXTERIOR EXPANDABLE PANEL OF SHEET MATERIAL HAVING PANEL-EDGES CONNECTED TO SAID FLANGE-FORMING STRIPS AT HINGING LINES PARALLEL TO SAID FOLDING LINES AND INTERMEDIATE THE EDGES OF SAID FLANGE-FORMING STRIPS, SAID PANEL HAVING AN EXPANDABLE WIDTH SUITABLE TO SPAN SAID DIMENSION WHEN THE OUTER EDGES OF THE FLANGE-FORMING STRIPS ARE SPACED APART BY SAID DIMENSION, SAID PANEL BEING CONTRACTED IN WIDTH BETWEEN SAID HINGING LINES WHEN SAID FLANGE-FORMING STRIPS ARE FOLDED TOWARD EACH OTHER ONTO SAID FACE OF SAID FACING MEANS. 